1.4 MPI engine (EA111) · Crankshaft group · Cylinder block, sealing flange

Renewing crankshaft sealing flange - flywheel end ( assembly tool - T10134- )

Special tools and workshop equipment required

  • Assembly tool - T10134-
  • Torque wrench (5 … 50 Nm) - V.A.G 1331-
  • Insert tool, 24 mm - V.A.G 1332/11-
  • Hexagon bolts (Qty. 3) M6×35 mm
  • Feeler gauge
  • Depth gauge

2.7.1 Pressing sealing flange with sender wheel off crankshaft

Sequence of operations

  • Remove engine speed sender - G28- -arrow-.
  • Unscrew sealing flange securing bolts.
  • Screw three M6×35 mm bolts into threaded holes -arrows- of sealing flange.
  • Screw bolts alternately (max. 1/2 turn (180°) for each bolt) into sealing flange and press sealing flange together with sender wheel off crankshaft.

2.7.2 Pressing sealing flange with sender wheel onto crankshaft

Assembly tool - T10134-

A - Clamping surface

B - Hexagon nut

C - Assembly housing

D - Locating pin

E - Hexagon socket head bolt

F - Guide pin for diesel engines (black knob)

G - Guide pin for petrol engines (red knob)

2.7.3 A - Assemble seal with sender wheel on assembly tool - T10134-.

  • Screw in hexagon nut -B- to just before clamping surface -A- of threaded spindle.
  • Clamp assembly device - T10134- in a vice on clamping surface -A- of threaded spindle.
  • Press assembly housing -C- downwards until it lies on hexagon nut -B- -arrow-.
  • Screw hexagon nut onto threaded spindle until inner part of assembly device and assembly housing are at same height.
  • Remove securing clip -arrow- from new sealing flange.
  • Locating hole -A- on sender wheel -C- must align with marking
    • B- on sealing flange.
  • Place sealing flange with front side downwards on a clean flat surface.
  • Push sealing lip support ring -A- downwards in direction of arrow until it lies on flat surface.
  • Upper edge of sender wheel and front edge of sealing flange must align -arrows-.
  • Place sealing flange with front side on assembly tool - T10134- so that locating pin -B- can be inserted in sender wheel hole
    • A-.
  • Push sealing flange and support ring for sealing lip -B- against surface of assembly tool - T10134- whilst tightening the three knurled screws -A- so that locating pin cannot slide out of sender wheel hole.

2.7.4 B - Fitting assembly tool - T10134- with sealing flange to crankshaft flange

  • Crankshaft flange must be free of oil and grease.
  • Engine positioned at TDC No. 1 cylinder.
  • Screw hexagon nut -B- to end of threaded spindle.
  • Press threaded spindle of assembly tool - T10134- in direction of arrow, until hexagon nut -B- lies against assembly housing
    • A-.
  • Align flat side of assembly housing on sump side of crankcase sealing surface.
  • Secure assembly tool - T10134- to crankshaft flange using hexagon socket head bolts -A-.
  • To guide sealing flange, screw two M6 × 35 mm bolts -A- into cylinder block.

2.7.5 C - Screwing assembly tool - T10134- on crankshaft flange

  • Push assembly housing -C- by hand in direction of arrow until sealing lip support ring -B- contacts crankshaft flange -A-.
  • Push guide pin for petrol engines (red knob) -F- into hole in crankshaft. This ensures that the sender wheel reaches its final installation position.
  • Hand-tighten both hexagon socket head bolts of assembly tool.
  • Screw hexagon nut -E- onto threaded spindle by hand until it lies on assembly housing -C-.

2.7.6 D - Pressing sender wheel onto crankshaft flange using assembly tool - T10134-

  • Tighten hexagon nut of assembly tool - T10134- to 35 Nm using torque wrench - V.A.G 1331- and tool insert 24 mm - V.A.G 1332/11-.

2.7.7 E - Checking sender wheel installation position on crankshaft

  • Screw hexagon nut -E- to end of threaded spindle.
  • Remove the two bolts -A- from cylinder block.
  • Screw the three knurled screws -B- out of sealing flange.
  • Remove assembly tool - T10134-.
  • Remove sealing lip support ring.
  • The sender wheel is in the correct installation position on the crankshaft if a gap -a- = 0.5 mm exists between crankshaft flange -A- and sender wheel -B-.
  • Set vernier gauge on crankshaft flange.
  • Measure distance -a- between crankshaft flange and sender wheel.

If dimension -a- is too small:

If dimension -a- is attained:

  • Tighten new securing bolts for sealing flange to 15 Nm using alternate and diagonal sequence.
  • Install engine speed sender - G28- -arrow- and tighten securing bolt to 5 Nm.
  • Install sump ⇒ 1.3 Removing and installing oil sump.
  • Install intermediate plate.
  • Install flywheel using new bolts. Tighten securing bolts to 60 Nm +1/4 turn (90°).

2.7.8 f) Re-pressing sender wheel

  • Secure assembly tool - T10134- to crankshaft flange using hexagon socket head bolts -A-.
  • Hand tighten both hexagon socket head bolts.
  • Push assembly tool - T10134- by hand to sealing flange.
  • Screw hexagon nut -E- onto threaded spindle by hand until it lies on assembly housing -C-.

If dimension -a- is still too small: